Casting Review
Casting Review
Casting Review
Raw Material
Melting and Solidification
of primary ingots
Down stream
manufacturing
processes
https://www.youtube.com/watch?v=zRUFzJrDtq0
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Nucleation
Homogenous = no ‘seed’ exists – so it takes a lot of cooling below the freezing point before solidification occurs.
Homogenous nucleation temp of water is -48°C. Practically never happens
Heterogenous = a ‘seed’ exists – some sort of platform on which atoms can attach. This may be impurities or
something deliberated added
Ultra-uniform, strong and ductile 3D printed titanium alloy through bifunctional alloy design
Jingqi Zhang, Michael J. Bermingham, Joseph Otte, Yingang Liu, Ziyong Hou, Nan Yang, Yu Yin, Mohamad Bayat, Weikang Lin, Xiaoxu Huang,
David H. StJohn, Matthew S. Dargusch, Science 383,639-645(2024).DOI:10.1126/science.adj0141
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Sand Casting
• Sand is the mould material – usually mixed with
chemicals to make it hard
• A pattern is used to create impression in the sand
• Molten metal poured into sand
• Mould is broken to extract cast part
• Can create quite complex parts by this method when
using cores
https://www.youtube.com/shorts/R6APnc0YXIo?feature=share
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Die Casting
• Steel Die is the mould material – so only lower melting
point metals that don’t react with steel can be cast
• Die needs to be manufactured, and often complex
machines used - $$$
• Molten metal can be poured in under gravity or by
pressure. In the lecture we discuss High Pressure DC
and Low Pressure DC
https://youtube.com/shorts/SDrAyixTbqs?si=xp-n71DTTA8kYVTo
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Investment Casting (lost wax casting)
• Wax pattern created → Ceramic slurry coats around the
wax to form mould → mould is sintered and wax melts
out → metal is poured in → part removed from ceramic
mould (broken out) → cleanup usually necessary (like
polishing etc.)
• Intricate parts from any metal can be cast since ceramic
has very high temperature tolerance
https://www.youtube.com/shorts/eYWK-0O-_-4
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Question & Answer
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Practice Exam Questions
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Which of the following is NOT correct?
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What factor reduces the fluidity of metal
castings?
A. Increase the pouring rate
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Which of the following is NOT associated
with good design for sand casting
A. Patterns should have appropriate taper to allow their
withdrawal from the sand without sand sticking to their
sides.
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Which of the following observations is NOT
a common cast defect in sand casting?
A. Hot tear
B. Shrinkage porosity
D. Equiaxed grains
E. Gas porosity
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Which of the following statements best describes the
functions of a riser (feeder) during sand casting?
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Which of the following is NOT correct?
A. In the design of moulds for sand castings the runner is
normally included in the drag, not in the cope
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Heat extraction
Chill to help
increase
solidification
rate
This large section is likely to solidify long after the thinner sections. Likely
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that the centre will contain shrinkage porosity due to lack of feeding
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Liquid
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= Sn = Pb
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Zircon (ZrO2)
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Creep
Micro-voids can form at grain boundaries during creep
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shrinkage
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Squeeze casting
Combination of casting and forging
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